U.S. patent application number 15/578839 was filed with the patent office on 2018-10-18 for cartridge and device for an aerosol-generating system.
This patent application is currently assigned to Philip Morris Products S.A.. The applicant listed for this patent is Philip Morris Products S.A.. Invention is credited to Nikolaus Martin Ernest Wilhelm RICKETTS.
Application Number | 20180295882 15/578839 |
Document ID | / |
Family ID | 53496526 |
Filed Date | 2018-10-18 |
United States Patent
Application |
20180295882 |
Kind Code |
A1 |
RICKETTS; Nikolaus Martin Ernest
Wilhelm |
October 18, 2018 |
CARTRIDGE AND DEVICE FOR AN AEROSOL-GENERATING SYSTEM
Abstract
There is provided a cartridge for an aerosol-generating system,
the cartridge including: a liquid storage container containing a
liquid aerosol-forming substrate including at least one flavor
object; an outlet; a filter disposed between the outlet and a
portion of the liquid storage container including the at least one
flavor object; and a liquid transport element, having a first part
and a second part, movable from a first position to a second
position, wherein in the first position the first part of the
liquid transport element is external to the cartridge and adjacent
the outlet, and in the second position the first part of the liquid
transport element is internal to the cartridge and remote from the
outlet.
Inventors: |
RICKETTS; Nikolaus Martin Ernest
Wilhelm; (Geneve, CH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Philip Morris Products S.A. |
Neuchatel |
|
CH |
|
|
Assignee: |
Philip Morris Products S.A.
Neuchatel
CH
|
Family ID: |
53496526 |
Appl. No.: |
15/578839 |
Filed: |
June 27, 2016 |
PCT Filed: |
June 27, 2016 |
PCT NO: |
PCT/EP2016/064886 |
371 Date: |
December 1, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24F 47/008 20130101;
A24B 15/167 20161101; A24D 1/002 20130101; A24B 13/02 20130101;
A24F 40/44 20200101; B01D 29/01 20130101; A24D 1/14 20130101; A24F
40/42 20200101 |
International
Class: |
A24F 47/00 20060101
A24F047/00; A24D 1/14 20060101 A24D001/14; A24D 1/00 20060101
A24D001/00; A24B 15/16 20060101 A24B015/16; A24B 13/02 20060101
A24B013/02; B01D 29/01 20060101 B01D029/01 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 29, 2015 |
EP |
15174395.2 |
Claims
1.-15. (canceled)
16. A cartridge for an aerosol-generating system, the cartridge
comprising: a liquid storage container, containing a liquid
aerosol-forming substrate, liquid of the liquid aerosol-forming
substrate including at least one flavor object; an outlet; a filter
disposed between the outlet and a portion of the liquid storage
container including the flavor object; and a liquid transport
element, having a first part and a second part, movable from a
first position to a second position, wherein in the first position
the first part of the liquid transport element is external to the
cartridge and adjacent the outlet, and in the second position the
first part of the liquid transport element is internal to the
cartridge and remote from the outlet.
17. The cartridge according to claim 16, wherein the liquid
includes a plurality of flavor objects.
18. The cartridge according to claim 16, wherein the at least one
flavor object is loose in the liquid storage container.
19. The cartridge according to claim 16, wherein the flavor object
is visible in the cartridge.
20. The cartridge according to claim 16, wherein the flavor object
comprises plant material.
21. The cartridge according to claim 16, wherein the filter is
movable between a first position and a second position in the
liquid storage container, the filter being closer to the outlet
when in the first position than when in the second position.
22. The cartridge according to claim 16, wherein the filter
comprises a mesh.
23. The cartridge according to claim 16, further comprising a loose
object in the liquid storage container, the loose object being
movable in a portion of the liquid storage container, and the loose
object being retained in the portion of the liquid storage
container by the filter.
24. An aerosol-generating device including a cartridge, the
cartridge comprising: a liquid storage container, containing a
liquid aerosol-forming substrate, liquid of the liquid
aerosol-forming substrate including at least one flavor object; an
outlet; a filter disposed between the outlet and a portion of the
liquid storage container including the flavor object; and a liquid
transport element, having a first part and a second part, movable
from a first position to a second position, wherein in the first
position the first part of the liquid transport element is external
to the cartridge and adjacent the outlet, and in the second
position the first part of the liquid transport element is internal
to the cartridge and remote from the outlet.
Description
[0001] The present invention relates to a cartridge for an
aerosol-generating system, and a device for receiving the
cartridge.
[0002] A number of prior art documents, for example EP-A-0 295 122,
EP-A-1 618 803 and EP-A-1 736 065, disclose electrically operated
smoking systems, having a number of advantages. One advantage of
some examples of such systems is that they can significantly reduce
sidestream smoke, while permitting the smoker to selectively
suspend and reinitiate smoking.
[0003] Prior art documents, such as EP-A-0 295 122, EP-A-1 618 803
and EP-A-1 736 065, disclose electrical smoking systems which use a
liquid as the aerosol-forming substrate. The liquid may be
contained in a cartridge which is receivable in a housing. A power
supply, such as a battery, is provided, connected to a heater to
heat the liquid substrate during a puff, to form the aerosol which
is provided to the smoker.
[0004] According to a first aspect of the present invention, there
is provided a cartridge for an aerosol-generating system. The
cartridge comprises a liquid storage container, containing a liquid
aerosol-forming substrate. The liquid includes at least one flavour
object.
[0005] Advantageously, the flavour object can provide flavour to
the aerosol-forming substrate. For example, the flavour object may
infuse the liquid with flavour. This addition of the flavour object
to the liquid may to provide the user with an improved experience
by changing the taste of the liquid. Where the content of the
liquid container can be seen by the user, the addition of a visible
flavour object may enhance the experience of the user. The flavour
object may comprise a solid material. Other alternatives are
possible. For example, the flavour object may be a gel or a
composite of more than one material or substance.
[0006] Preferably the liquid contains a plurality of flavour
objects. The liquid may for example include more than 5, more than
10, or 20 or more flavour objects.
[0007] The flavour objects may be all similar or substantially the
same, for example in size, shape or composition. In some examples,
more than one different flavour object is included in the liquid.
The different flavour objects may be different in one or more
aspect including size, shape and composition. A flavour object may
be for example a particle, granule, pellet, flake, leaf, stick,
shred, spaghetti, or strip. The flavour object may for example have
a maximum dimension of 4 mm. For example the flavour object may
have dimensions less than 3 mm, for example less than 2 mm or less
than 1 mm. In some examples, the flavour object will be larger than
about 0.1 mm, preferably larger than 0.2 mm, for example larger
than 0.5 mm. Where reference is made to the object being larger
than a particular size, preferably the object does not pass through
a sieve having a mesh opening of that particular size.
[0008] For example where the flavour object is in the form of a
flake or leaf, the object may for example have a width between
about 0.1 mm and about 3 mm, preferably between about 0.2 mm and
about 2 mm. The flavour object may have a length between about 0.5
mm and about 4 mm, preferably between about 0.7 mm and about 3 mm.
The flavour object may have an average thickness between about 20
.mu.m and about 550 .mu.m, preferably between about 30 .mu.m and
about 120 .mu.m.
[0009] Preferably the flavour object is visible in the liquid.
Preferably the size of the flavour object is such that the object
is visible in the liquid by the user. Preferably the flavour object
is visible in the cartridge by the user. In some examples, the
flavour object is visible to the user during use of an aerosol
generating system. The flavour object may be visible to the user
when the cartridge is installed in an aerosol generating
device.
[0010] In examples of the invention, the flavour object comprises
plant material. The flavour object may comprise a leaf, stem,
stalk, flower, fruit, root or other part of a plant. The flavour
object may comprise a herb. The flavour object may comprise a
botanical. The flavour object may comprise tobacco. The flavour
object may comprise one or more of: powder, granules, pellets,
flakes, shreds, spaghettis, or strips containing one or more of:
herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted
tobacco, homogenised tobacco, extruded tobacco and expanded
tobacco. The flavour object may comprise one or more of mint,
rosemary, sage, or other herb. The liquid may further include one
or more additional objects which may or may not impart a flavour to
the liquid. In a further aspect of the invention there is provided
a liquid storage container including liquid aerosol forming
substrate, the liquid aerosol forming substrate including a
plurality of objects. The objects may have one or more of the
features of the flavour objects described herein.
[0011] The liquid aerosol-forming substrate may further comprise
flavour components in liquid form. The liquid may comprise a
tobacco-containing material containing volatile tobacco flavour
compounds which are released from the substrate upon heating. The
aerosol-forming substrate may comprise a non-tobacco material. The
aerosol-forming substrate may comprise tobacco-containing material
and non-tobacco containing material. Preferably, the
aerosol-forming substrate further comprises an aerosol former.
Examples of suitable aerosol formers are glycerine and propylene
glycol.
[0012] Preferably the flavour object is loose or free in the liquid
storage container. In preferred examples of the invention, the
flavour object can move in the liquid in the liquid storage
container. In some examples, the flavour object may float or be
suspended in the liquid. Where the liquid includes a plurality of
the flavour objects, the liquid and flavour objects may form a
suspension or a colloid. The properties of the liquid and objects
may be selected or modified to achieve a desired distribution of
the objects in the liquid. For example some of all of the objects
may tend to float, sink or be suspended in the liquid. Such
properties may be achieved for example by selection of
compositions, treatments, coatings or by other means.
[0013] Preferably, the cartridge further comprises an outlet, and a
filter arranged between the outlet and a portion of the liquid
storage container including the flavour object. Preferably, the
outlet is for delivery of aerosol-forming substrate from the liquid
storage container.
[0014] Advantageously, providing a liquid aerosol-forming substrate
having a solid flavour object, and a filter between the outlet and
that solid flavour object enables a liquid aerosol-forming
substrate to be provided which has the advantages of both a liquid
and solid aerosol-forming substrate without the difficulty of
generating an aerosol directly from a solid substrate without, for
example, burning the substrate. The solid flavour object may infuse
the liquid aerosol-forming substrate with additional flavour. This
maceration process may enable the liquid aerosol-forming substrate
to be fresher, and provide the user with an improved
experience.
[0015] Preferably, the filter is movable between a first position
adjacent the outlet and a second position remote from the first
position in the liquid storage container. In the second position,
the or each solid flavour object is separated from the bulk of the
liquid and distant from the outlet. The filter is preferably closer
to the outlet when in the first position than when in the second
position.
[0016] Advantageously, providing a cartridge having a movable
filter enables an aerosol-forming substrate having at least one
solid flavour object to be provided which enables the liquid
composition to be prepared immediately prior to use without the or
each solid flavour object interfering with the transfer of liquid
out of the cartridge during use. The or each solid flavour object
may enable the liquid aerosol-forming substrate to be infused with
additional flavour. This maceration process may enable the liquid
aerosol-forming substrate to be fresher, and provide the user with
an improved experience. Conventional electrically heated
aerosol-generating devices cannot use such an advantageous
combination of liquid substrate and solid flavour object since the
device would become clogged, and the solid flavour object could
potentially be burnt by the heating element.
[0017] Where the liquid aerosol-forming substrate and the or each
solid flavour object are in a suspension, the filter preferably
acts to take the or each solid flavour objects out of suspension in
the liquid.
[0018] The cartridge may further comprise a loose object in the
liquid storage container, the loose object being movable in a
portion of the liquid storage container, the loose object being
retained in the portion of the liquid storage container by the
filter.
[0019] The cartridge may further comprise a heating element, the
filter being arranged in the liquid storage container and spaced
apart from the heating element. Further details of the heating
element are provided below.
[0020] The cartridge may further comprise a liquid transport
element, having a first part and a second part, movable from a
first position to a second position. In the first position the
first part of the liquid transport element is external to the
cartridge and adjacent the outlet, and in the second position the
first part of the liquid transport element is internal to the
cartridge and remote from the outlet. The liquid transport element
may further comprise a heating element adjacent the second part of
the liquid transport element. The liquid transport element is
preferably an elongate shaft, and is preferably substantially
rigid.
[0021] The filter is preferably configured to receive an end of the
liquid transport element received by the outlet, wherein in use,
the liquid transport element acts on the filter to move the filter
from the first position to the second position.
[0022] The filter preferably comprises a through hole configured to
receive the end of the liquid transport element. The filter
preferably comprises a porous disc having a recess, the filter
disposed in the recess. The thickness of the porous disc is
preferably configured such that the porous disc remains
substantially perpendicular to a longitudinal axis of the liquid
storage container as the filter moves from the first position to
the second position. The thickness of the porous disc may be
between about 50 .mu.m and about 400 .mu.m, preferably between
about 70 .mu.m and about 200 .mu.m. The porous disc preferably
comprises the through hole. The porous disc may comprise a
plurality of perforations. The porous disc may comprise a mesh,
preferably a coarse mesh. The porous disc may be moulded from a
polymer, such as any of the polymers suitable for forming the
canister described above. On receipt of a liquid transport element
in the through hole, the filter is preferably configured such that
the liquid transport element engages with the filter. The inner
diameter of the through hole is preferably such that the liquid
transport element is an interference fit within the porous
disc.
[0023] The cartridge preferably further comprises a seal configured
to seal the outlet. The seal may be frangible. The seal may be
removable. The seal may be formed from a film. The film may be
formed of a metal film, preferably aluminium, more preferably food
grade, anodised aluminium, or a polymer such as polypropylene,
polyurethane, polyethylene, fluorinated ethylene propylene.
[0024] The seal may be formed from a laminate film. At least one
layer of the laminate material may be paper or cardboard. The
layers of the laminate may be bonded together using adhesive, heat,
or pressure. When the laminate comprises a layer of aluminium and a
layer of polymer material, the polymer material may be a coating.
The coating layer may be thinner than the aluminium layer.
[0025] When the cartridge comprises a frangible seal, the first
part of the liquid transport element may comprise a piercing
portion, configured to pierce the seal. The first part of the
liquid transport element may comprise at least one ridge,
configured to engage with the filter element.
[0026] The internal diameter of the outlet is preferably such that
there is a close sliding fit between the outlet and the liquid
transport element. Therefore, when the liquid transport element is
in the second position, resistance to liquid leakage between the
external surface of the liquid transport element and the outlet is
improved. The internal diameter of the outlet may be between about
1.5 mm and about 7 mm, preferably between about 2 mm and about 5
mm, more preferably between about 1.8 mm and about 2.3 mm. The
external diameter of the liquid transport element may be between
about 1.5 mm and about 7 mm, preferably between about 2 mm and
about 5 mm, more preferably about 1.8 mm and about 2.3 mm. The
tolerance between the internal diameter of the outlet and the
external diameter of the liquid transport element is preferably
between about 0.05 mm and about 0.3 mm, preferably 0.1 mm and about
0.15 mm.
[0027] The outlet may comprise a flexible gasket configured to
deform on receipt of the liquid transport element in the outlet.
Such a flexible gasket improves the resistance to leakage between
the external surface of the liquid transport element and the
outlet. The flexible gasket may be an elastomer or a polymer, such
as graphene.
[0028] Where the cartridge comprises a liquid transport element,
the cartridge may further comprise a protective sheath, coupled to
the liquid transport element and configured to slidably engage with
the liquid storage container of the cartridge. The protective
sheath advantageously protects the liquid transport element from
damage, or contamination, when the liquid transport element is in
the first position. The protective sheath is preferably cylindrical
having an open part and a closed part, the internal diameter of the
cylinder being such that a close sliding fit is provided between
the internal surface of the sheath and the external surface of the
liquid storage container.
[0029] The liquid transport element may further comprise at least
one heating element adjacent the second part of the liquid
transport element. The at least one heating element preferably
comprises electrical contacts configured to enable an electrical
connection to be made to a power supply. Further details of the at
least one heating element are provided below. Where a protective
sheath is provided, the second part of the liquid transport element
comprising the at least one heating element may protrude through
the closed end of the sheath.
[0030] The liquid transport element may comprise a capillary wick.
The capillary wick may be formed from capillary fibres, including
glass fibres, carbon fibres, and metallic fibres, or a combination
of any and all of glass fibres, carbon fibres and metallic fibres.
Providing metallic fibres may enhance the mechanical resistance of
the wick without negatively affecting the hydrophobic properties of
the overall wick. Such fibres may be provided parallel to the
central axis of the wick, and may be braided, twisted or partially
non-woven. Preferably, when the liquid transport element is in the
second position, the capillary wick is arranged to be in contact
with liquid in the liquid storage container. In that case, in use,
liquid is transferred from the liquid storage container towards the
at least one electric heating element by capillary action in the
capillary wick. When the heating element is activated, liquid in
the capillary wick is vaporised by the heating element to form the
supersaturated vapour. The supersaturated vapour is mixed with and
carried in the airflow. During the flow, the vapour condenses to
form the aerosol and the aerosol is carried towards the mouth of a
user. The heating element in combination with a capillary wick may
provide a fast response, because that arrangement may provide a
high surface area of liquid to the heating element. Control of the
heating element according to the invention may therefore depend on
the structure of the capillary wick or other heating arrangement.
Further detail regarding the heating element and the control
thereof is provided below.
[0031] The liquid storage container preferably has a circular
cross-section. The liquid storage container may have an oval,
rectangular, square, triangular, or similar cross-section.
Preferably, the outer diameter of the filter is such that the
filter is a close sliding fit within the liquid storage container.
Arranging the liquid storage container and the filter such that
there is a close sliding fit improves the filtering to reduce or
eliminate the presence of solid flavour objects in the bulk of the
liquid aerosol-forming substrate when the filter is in the second
position. The filter may comprise a seal, such as an o-ring,
configured to slide against the inner surface of the liquid storage
container.
[0032] The cartridge preferably has the same cross-sectional shape
as the liquid storage container.
[0033] The filter may comprise capillary fibres. The filter may be
formed by welding a mat of capillary fibres. The welding may be
ultrasonic welding. The filter may have a thickness between about
10 .mu.m and about 110 .mu.m, preferably between about 20 .mu.m and
about 70 .mu.m. The filter may be formed from a woven, or non-woven
material. The fibres of the woven, or non-woven material may be
parallel, twisted, braided, or a combination of any or all of these
types of fibres. The filter may comprise a single material, or a
plurality of materials. The material may be a metal, or a non-metal
natural, synthetic, or both natural and synthetic material.
Preferably, the fibres of the filter are formed from cellulose.
Preferably the filter is formed from non-woven cellulose fibres.
Alternatively, the filter is formed from a mesh, preferably a
stainless steel mesh, more preferably medical grade stainless
steel.
[0034] The liquid storage container may comprise a canister having
a closed end and an open end, and a lid comprising the outlet. The
canister may comprise a lip, and the lid may comprise a projection,
the lip and projection are configured to engage to fix the lid to
the canister. The liquid storage container may be a thin-walled
canister. The canister may be formed from a substantially
transparent material, such as ALTUGLAS.RTM. Medical Resins
Polymethlymethacrylate (PMMA), Chevron Phillips K-Resin.RTM.
Styrene-butadiene copolymer (SBC), Arkema special performance
polymers Pebax.RTM., Rilsan.RTM., and Rilsan.RTM. Clear, DOW
(Health+.TM.) Low-Density Polyethylene (LDPE), DOW.TM. LDPE 91003,
DOW.TM. LDPE 91020 (MFI 2.0; density 923), ExxonMobil.TM.
Polypropylene (PP) PP1013H1, PP1014H1 and PP9074MED, Trinseo
CALIBRE.TM. Polycarbonate (PC) 2060-SERIES. The canister may be
moulded, such as by in an injection moulding process.
[0035] An advantage of providing a cartridge is that a high level
of hygiene can be maintained. Using a liquid transport element,
such as a capillary wick, extending between the liquid and the
electric heating element, allows the structure of the device to be
relatively simple. The liquid has physical properties, including
viscosity and surface tension, which allow the liquid to be
transported through the liquid transport element, such as by
capillary action. The cartridge is preferably not be refillable.
Thus, when the liquid in the liquid storage container has been used
up, the aerosol generating device is replaced. Preferably, the
liquid storage container is arranged to hold liquid for a
pre-determined number of puffs.
[0036] Where the liquid transport element comprises a capillary
wick, the capillary wick may have a fibrous or spongy structure.
The capillary wick preferably comprises a bundle of capillaries.
For example, the capillary wick may comprise a plurality of fibres
or threads, or other fine bore tubes. The fibres or threads may be
generally aligned in the longitudinal direction of the aerosol
generating device. The capillary wick may comprise sponge-like or
foam-like material formed into a rod shape. The structure of the
wick forms a plurality of small bores or tubes, through which the
liquid can be transported to the at least one heating element, by
capillary action. The capillary wick may comprise any suitable
material or combination of materials. Examples of suitable
materials are ceramic- or graphite-based materials in the form of
fibres or sintered powders. The capillary wick may have any
suitable capillarity and porosity so as to be used with different
liquid physical properties such as density, viscosity, surface
tension and vapour pressure. The capillary properties of the wick,
combined with the properties of the liquid, ensure that the wick is
always wet in the heating area.
[0037] The liquid transport element may further comprise a conduit
having a first portion and a second portion. The conduit is
configured such that, when the liquid transport element is in the
first position, the first portion and the second portion of the
conduit are external to the liquid storage container, and, when the
liquid transport element is in the second position, the first
portion of the conduit is internal to the liquid storage container,
and the second portion of the conduit is external to the liquid
storage container. When the liquid transport element is in the
second position, the conduit is preferably configured to transport
liquid from within the liquid storage container to without the
liquid storage container. The conduit may be hollow. The conduit
may comprise capillary material. The conduit may have a heating
element disposed therein.
[0038] According to a second aspect of the present invention, there
is provided an aerosol-generating device configured to receive a
cartridge having a liquid transport element and heating element as
described herein. The device comprises: a housing having a cavity
for receiving the cartridge; a power supply; and electrical
contacts configured to couple the heating element of the cartridge
to the power supply when the cartridge is received in the
cavity.
[0039] The device of the second aspect may further comprise an
actuator configured to move the liquid transport element from the
first position to the second position when the cartridge is
received in the cavity. The actuator may be an electrically
operated actuator. The electrically operated actuator may be
actuated when a cartridge is received in the cavity of the housing.
The actuator may be a mechanically operated actuator. The
mechanically operated actuator may be user operated. The housing
may comprise a lid configured to close the cavity. The lid may be a
hinged lid configured to move from a first, open, position to a
second, closed position. In the first position, the cartridge may
be inserted into the cavity. Where present, the mechanically
operated actuator may be coupled to the lid. The action of closing
the lid may operate the mechanical actuator to move the liquid
transport element from the first position to the second position.
The actuator preferably engages the electrical contacts of the
device with corresponding electrical contacts on the cartridge to
enable power to be supplied to the at least one heater of the
cartridge.
[0040] Alternatively to providing an actuator, the user may apply a
longitudinal compressive force to the cartridge to move the liquid
transport element from the first position to the second position,
and then insert the cartridge into the device.
[0041] According to a third aspect of the present invention, there
is provided an aerosol-generating device configured to receive a
cartridge without a liquid transport element as described herein.
The device comprises: a housing having a cavity for receiving the
cartridge; a liquid transport element, having a first part and a
second part, the first end being insertable into the outlet of the
cartridge; a heating element adjacent the second part of the liquid
transport element; and a power supply configured to supply power to
the heating element.
[0042] The device of the third aspect may further comprise an
actuator configured to engage the cartridge with the liquid
transport element when the cartridge is received in the cavity,
such that the liquid transport element is inserted into the
cartridge. The actuator may be an electrically operated actuator.
The electrically operated actuator may be actuated when a cartridge
is received in the cavity of the housing. The actuator may be a
mechanically operated actuator. The mechanically operated actuator
may be user operated. The housing may comprise a lid configured to
close the cavity. The lid may be a hinged lid configured to move
from a first, open, position to a second, closed position. In the
first position, the cartridge may be inserted into the cavity.
Where present, the mechanically operated actuator may be coupled to
the lid. The action of closing the lid may operate the mechanical
actuator to move the cartridge towards the liquid transport element
such that the liquid transport element is moved into the cartridge
from the first position to the second position.
[0043] The device of the third aspect preferably further comprises
a shield movable from a first position to a second position,
wherein in the first position the shield is adjacent the first part
of the liquid transport element, and in the second position the
shield is adjacent the second part of the liquid transport element,
wherein the shield is biased towards the first position. The shield
advantageously protects the liquid transport element from damage of
contamination before a cartridge is inserted into the cavity.
[0044] The device preferably comprises a mouthpiece. As used
herein, the term "mouthpiece" preferably refers to a portion of an
aerosol-generating system, an aerosol-generating article, or the
aerosol-generating device, that is placed into a user's mouth in
order to directly inhale an aerosol generated by the
aerosol-generating system. The mouthpiece may be removable. The
mouthpiece may comprise, or be, a lid for closing the cavity.
[0045] The aerosol-generating device may comprise an
aerosol-forming chamber in which aerosol forms from a super
saturated vapour, which aerosol is then carried into the mouth of a
user. An air inlet, air outlet and the chamber are preferably
arranged so as to define an airflow route from the air inlet to the
air outlet via the aerosol-forming chamber, so as to convey the
aerosol to the air outlet and into the mouth of a user. In use, the
second end of the liquid transport element is preferably disposed
within the aerosol-forming chamber. The air inlet may be provided
in a mouthpiece. The air outlet may be provided in the mouthpiece.
A portion of the cavity for receiving the cartridge may form the
aerosol-forming chamber. The airflow path may extend from the air
inlet, through the aerosol-forming chamber, around the cartridge,
and to the air outlet.
[0046] The mouthpiece may be formed from medical adequate polymeric
compounds, including grade polymers, including using DuPont.TM.
Delrin acetal and Zytel.RTM. nylon resins, as well as Altuglas.RTM.
PMMA, Celanex.RTM. PBT, ExxonMobil.TM. PP--Medical Grades,
Fortron.RTM. PPS, Hostaform.RTM. POM, K-Resin.RTM. SBC, LD PE
Health+.TM. Dow, Pebax.RTM. TPE-A, Riteflex.RTM. TPE-E, Vectra.RTM.
LCP. The mouthpiece may comprise a coating, such as a polymeric
coating.
[0047] The device housing, preferably the outer body, may comprise
the part that is held by the user. The device housing may comprise
a coating, preferably the coating is the same as the coating, where
provided, on the mouthpiece.
[0048] The device may comprise more than one heating element, for
example two, or three, or four, or five, or six or more heating
elements. The heating element or heating elements may be arranged
appropriately so as to most effectively heat the aerosol-forming
substrate.
[0049] The at least one electric heating element preferably
comprises an electrically resistive material. Suitable electrically
resistive materials include but are not limited to: semiconductors
such as doped ceramics, electrically "conductive" ceramics (such
as, for example, molybdenum disilicide), carbon, graphite, metals,
metal alloys and composite materials made of a ceramic material and
a metallic material. Such composite materials may comprise doped or
undoped ceramics. Examples of suitable doped ceramics include doped
silicon carbides. Examples of suitable metals include titanium,
zirconium, tantalum and metals from the platinum group. Examples of
suitable metal alloys include stainless steel, Constantan, nickel-,
cobalt-, chromium-, aluminium-titanium-zirconium-, hafnium-,
niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-,
manganese- and iron-containing alloys, and super-alloys based on
nickel, iron, cobalt, stainless steel, Timetal.RTM., iron-aluminium
based alloys and iron-manganese-aluminium based alloys.
Timetal.RTM. is a registered trade mark of Titanium Metals
Corporation, 1999 Broadway Suite 4300, Denver Colo. In composite
materials, the electrically resistive material may optionally be
embedded in, encapsulated or coated with an insulating material or
vice-versa, depending on the kinetics of energy transfer and the
external physicochemical properties required. The heating element
may comprise a metallic etched foil insulated between two layers of
an inert material. In that case, the inert material may comprise
Kapton.RTM., all-polylmide or mica foil. Kapton.RTM. is a
registered trade mark of E.I. du Pont de Nemours and Company, 1007
Market Street, Wilmington, Del. 19898, United States of
America.
[0050] The at least one electric heating element may comprise an
infra-red heating element, a photonic source, or an inductive
heating element.
[0051] The at least one electric heating element may take any
suitable form. The at least one electric heating element may take
the form of a casing or substrate having different
electro-conductive portions, or an electrically resistive metallic
tube. The cartridge may incorporate a disposable heating element.
The at least one electric heating element may be a disk (end)
heating element or a combination of a disk heating element with
heating needles or rods. The at least one electric heating element
may comprise a flexible sheet of material arranged to surround or
partially surround the aerosol-forming substrate. Other
possibilities include a heating wire or filament, for example a
Ni--Cr, platinum, tungsten or alloy wire, or a heating plate.
Optionally, the heating element may be deposited in or on a rigid
carrier material.
[0052] The at least one electric heating element may comprise a
heat sink, or heat reservoir comprising a material capable of
absorbing and storing heat and subsequently releasing the heat over
time to the aerosol-forming substrate. The heat sink may be formed
of any suitable material, such as a suitable metal or ceramic
material. Preferably, the material has a high heat capacity
(sensible heat storage material), or is a material capable of
absorbing and subsequently releasing heat via a reversible process,
such as a high temperature phase change. Suitable heat storage
materials include silica gel, alumina, carbon, glass mat, glass
fibre, minerals, a metal or alloy such as aluminium, silver or
lead, and a cellulose material such as paper. Other materials which
release heat via a reversible phase change include paraffin, sodium
acetate, naphthalene, wax, polyethylene oxide, a metal, metal salt,
a mixture of eutectic salts or an alloy.
[0053] The heat sink or heat reservoir may be arranged such that it
is directly in contact with the aerosol-forming substrate and can
transfer the stored heat directly to the substrate. The heat stored
in the heat sink or heat reservoir may be transferred to the
aerosol-forming substrate by means of a heat conductor, such as a
metallic tube.
[0054] The at least one heating element may heat the
aerosol-forming substrate by conduction. The heating element may be
at least partially in contact with the substrate, or the carrier on
which the substrate is deposited. The heat from the heating element
may be conducted to the substrate by a heat conductive element.
[0055] The at least one heating element may transfer heat to the
incoming ambient air that is drawn through the electrically heated
aerosol generating device during use, which in turn heats the
aerosol-forming substrate by convection. The ambient air may be
first drawn through the substrate and then heated.
[0056] Control of the at least one electric heating element may
depend upon the physical properties of the liquid substrate, such
as the boiling point, vapour pressure, and surface tension.
[0057] The device may comprise control circuitry configured to
control the supply of power from the power supply to the or each
heating element. The control circuitry may comprise a puff sensor
configured to detect when a user draws on the device, the control
circuitry activates the heater when a puff is detected. The device
may comprise a user input, such as a switch, for activating the
device.
[0058] The power supply may be an external electric power supply or
an on-board electric power supply. The power supply may be AC or
DC, preferably DC. The power supply may be a battery. The power
supply may alternatively be another form of charge storage device
such as a capacitor. The power supply may require recharging and
may have a capacity that allows for the storage of enough energy
for one or more smoking experiences; for example, the power supply
may have sufficient capacity to allow for the continuous generation
of aerosol for a period of around six minutes, corresponding to the
typical time taken to smoke a conventional cigarette, or for a
period that is a multiple of six minutes; in another example, the
power supply may have sufficient capacity to allow for a
predetermined number of puffs or discrete activations of the
heater.
[0059] Preferably, the aerosol generating device is portable. The
aerosol generating device may be a smoking device and may have a
size comparable to a conventional cigar or cigarette. The smoking
device may have a total length between approximately 30 mm and
approximately 150 mm. The smoking device may have an external
diameter between approximately 5 mm and approximately 30 mm.
[0060] According to a fourth aspect of the present invention, there
is provided an aerosol-generating device configured to releasably
receive a cartridge as described herein. The device comprises a
power supply for powering a heating element arranged to heat liquid
aerosol-forming substrate delivered to the heating element from the
liquid storage container, to generate an aerosol.
[0061] According to a fifth aspect of the present invention, there
is provided an aerosol-generating device including a cartridge as
described herein. The device may be disposable, in that the
cartridge may not be refillable or replaceable after use.
[0062] According to a further aspect of the present invention,
there is provided an electrically heated aerosol-generating system
comprising a cartridge as described herein, and an
aerosol-generating device as described herein.
[0063] Any feature in one aspect of the invention may be applied to
other aspects of the invention, in any appropriate combination. In
particular, method aspects may be applied to apparatus aspects, and
vice versa. Furthermore, any, some or all features in one aspect
can be applied to any, some or all features in any other aspect, in
any appropriate combination.
[0064] It should also be appreciated that particular combinations
of the various features described and defined in any aspects of the
invention can be implemented and/or supplied and/or used
independently.
[0065] The disclosure extends to methods and apparatus
substantially as herein described with reference to the
accompanying drawings.
[0066] The invention will be further described, by way of example
only, with reference to the accompanying drawings in which:
[0067] FIG. 1 shows a cartridge according to one embodiment of the
present invention;
[0068] FIG. 2 shows an aerosol-generating device according to one
embodiment of the present invention;
[0069] FIG. 3 shows a system comprising the aerosol-generating
device of FIG. 2 with the cartridge of FIG. 1;
[0070] FIGS. 4(a) and 4(b) shows the system of FIG. 3 in use;
[0071] FIG. 5 shows a cartridge according to an alternative
embodiment of the present invention;
[0072] FIG. 6 shows an aerosol-generating device according to an
alternative embodiment of the present invention;
[0073] FIG. 7 shows a cartridge according to an alternative
embodiment of the present invention;
[0074] FIG. 8 shows an exploded view of the cartridge shown in FIG.
7;
[0075] FIGS. 9(a), 9(b) and 9(c) show an aerosol-generating device
according to a further alternative embodiment of the present
invention; and
[0076] FIG. 10 shows a detailed view of a heater assembly of the
aerosol-generating device show in FIG. 9.
[0077] FIG. 1 shows a cartridge 100, comprising a liquid storage
container in the form of canister 102, a lid 104 having an outlet
106, and a filter element 108. The canister 102 comprises a liquid
aerosol-forming substrate 110 having flakes of solid tobacco
material 112. As used herein, "flakes of solid tobacco material"
refers to leaves of tobacco, shreds of homogenised tobacco, or the
like. The liquid aerosol-generating substrate comprises a
nicotine-containing material and an aerosol former such as
propylene glycol or glycerine, which are released from the
aerosol-forming substrate upon heating. The solid tobacco material
is macerated in the liquid to impart tobacco flavor compounds which
are also released upon heating.
[0078] The canister 102 is cylindrical and has a closed end 114 and
an open end 116. The canister is sealed by the lid 104, and a
frangible film disposed over the outlet 106. The lid comprises a
protrusion 118 around the circumference of the lid which engages
with a corresponding lip 120 adjacent the open end of the canister.
The lid further comprises a flexible gasket 122 configured to
receive a liquid transport element, which is described in further
detail below.
[0079] The canister 102 may be substantially transparent to allow
the user to view the contents of the cartridge 100.
[0080] The filter element 108 comprises a porous disc 124 and a
filter 126. The porous disc 124 comprises a porous base 128 in the
form of a coarse mesh. The filter 126 is formed of capillary fibres
which are ultrasonically welded together. The filter is affixed to
the underside of the porous base 128. The porous disc 124 further
comprises a through hole 130 configured to receive a liquid
transport element.
[0081] In use, the filter element is configured to be movable to
strain the solid tobacco flakes from the liquid, and move the
flakes away from the outlet 106.
[0082] As can be seen, the filter element 108 has an external
diameter such that a close sliding fit is provided in the canister
102. In this way, the tobacco flakes are prevented from passing
around the filter element as the filter element moves along the
canister. The thickness of the porous disc 124 is such that the
disc remains substantially perpendicular to the longitudinal axis
of the cartridge as it moves from the position shown in FIG. 1, the
first position, to a position adjacent the closed end 114, the
second position.
[0083] Such a cartridge enables the tobacco flakes to macerate in
the liquid until just before use in an aerosol-generating device,
imparting tobacco flavour to the liquid aerosol-forming
substrate.
[0084] FIG. 2 shows an aerosol-generating device 200 configured to
receive and use the cartridge 100. The device 200 comprises an
outer housing 202, a removable mouthpiece 204, a power supply 206
in the form of a rechargeable battery, control circuitry 208, and a
cavity 210 configured to receive a cartridge 100. The cavity 210
comprises a liquid transport element 212 having a first, free, end
214 and a second end 216 attached to the device 200. The liquid
transport element 212 comprises a resistive heating element 218
adjacent the second end 216. The heating element 218 is
electrically coupled to the power supply 206 via the control
circuitry 208. The first end 214 of the liquid transport element
212 comprises ridges configured to both pierce the frangible seal
on the cartridge 100, and to engage with the filter 126. The liquid
transport element 212 is a capillary wick for transporting liquid
from the canister 102 of a cartridge 100 to the heating element
218.
[0085] The cavity further comprises a shield 220. The shield is
biased, for example by a spring, towards the mouthpiece end of the
device, and is configured to slide over the liquid transport
element 212. The shield protects the liquid transport element 212
from damage and contamination when the device is not in use. An air
inlet (not shown), and an air outlet in the mouthpiece (not shown)
are provided, together with an airflow pathway which extends from
the air inlet to the air outlet via the cavity.
[0086] FIG. 3 shows the device 200 with a cartridge 100 inserted in
the cavity 210. FIGS. 4(a), 4(b) and 4(c) show the process of the
user inserting the cartridge 100 into the device 200. In use, the
user removes the mouthpiece 204 to open the cavity 210. The user
then inserts the cartridge 100 into the cavity 210. The cartridge
engages with the shield 220 which guides the cartridge 100 such
that the liquid transport element 212 first pierces the frangible
seal, and then moves through the flexible gasket 122, and engages
with the through hole 130 of the porous disc 124. As the cartridge
100 is inserted further into the cavity, the liquid transport
element 212 moves the filter element 108 from the first position
(shown in FIG. 1) to the second position (shown in FIGS. 3 and
4(c)) such that the tobacco flakes are strained from the liquid 110
and moved away from the heating element 216. If the tobacco flakes
are not moved away from the heating element, they may burn in use.
As can be seen, the ridges on the first end 214 of the liquid
transport element 212 enable liquid to be drawn into the end of the
liquid transport element.
[0087] In use, the user activates the device, either by drawing on
the mouthpiece which activates a puff sensor, or by a switch. The
heating element 218 is then provided with power from the power
supply 206, liquid in the capillary wick is vaporised by the
heating element to form a supersaturated vapour. The vapour is then
entrained in the airflow generated by the user drawing on the
device, and forms an aerosol. Further liquid is drawn along the
liquid transport 212 element by capillary action.
[0088] The outer housing 202 in the region of the cavity 210 may be
substantially transparent to allow the user to view the contents of
the cartridge 100.
[0089] An alternative example of a cartridge 500 is shown in FIG.
5(a). The cartridge 500 is similar to that shown in FIG. 1. The
cartridge 500 again comprises a canister 502, lid 504 having an
outlet 506, filter element 508, and liquid aerosol-forming
substrate 510 comprising solid tobacco flakes 512. In this example
the cartridge 500 comprises the liquid transport element 514
coupled to the filter element 508. The liquid transport element 514
may be the same as the liquid transport element 212 of device 200,
or it may not be formed from a capillary wick. In the example,
shown the liquid is transported by a tube 516 provided at the
second end of the liquid transport element. The tube 516, shown in
detail in FIG. 5(b), has a pair of inlets 518 in the shaft of the
liquid transport element, and an outlet 520 at the second end of
the liquid transport element. As will now be appreciated, in use,
the liquid transport element is moved from the first position shown
in FIG. 5(a) to a second position such that the pair of inlets for
the tube 516 are within the canister and are able to transport
liquid to an external heating element.
[0090] The cartridge may be used in a device 600 such as that shown
in FIG. 6. The device is similar to that shown in FIG. 2, and
comprises an outer housing 602, a mouthpiece 604, a power supply
606 and control electronic 608. The housing 602 comprises a cavity
610 for receiving a cartridge having an integral liquid transport
element, such as cartridge 500 described above. The cavity is
provided with a lid 612 configured to cover and close the cavity in
use. The lid comprises a mechanism 614 for forcing the liquid
transport element from the first position to the second position
when the lid is closed by the user. The lid may be substantially
transparent to enable the user to view the straining process as the
lid is closed. The device 600 further comprises a heating element
disposed in the cavity 610 for heating the liquid transported by
the tube 516.
[0091] Once the lid is closed, the device 600 operates in the same
manner as described above in relation to the device of FIG. 2.
[0092] FIG. 7 shows a cartridge 700, comprising a liquid storage
container in the form of canister 702. The canister 702 comprises a
central hollow portion 704, and an outlet 706 provided at one end
of the central hollow portion. At one end of the central hollow
portion 704, a frangible seal 708 is provided to seal the outlet
706 before use. A partition 710 is provided which divides the
canister 702 into two liquid storage portions 712 and 714. At the
end of the canister 702 having the outlet 706 a liquid delivery
assembly is provided. The liquid delivery assembly comprises a
filter element 716, and a porous capillary element 718. The porous
capillary element 718 is formed from a high retention material to
reduce or prevent leakage from the cartridge during use. The two
liquid storage portions 712 and 714 are in fluid communication.
This can be achieved either through the liquid delivery assembly,
or by forming the partition 710 from a fluid permeable, or
semi-permeable material.
[0093] The canister 702 is transparent and comprises two liquid
aerosol-forming substrates, one in each of the two liquid storage
portions 712 and 714. One of the liquid aerosol-forming substrates
comprises flakes of solid tobacco material 720, similar to those
described above with regards to FIG. 1. The solid material may be
any other type of flavour imparting material as described herein.
The liquid aerosol-forming substrate comprises a
nicotine-containing material and an aerosol former such as
propylene glycol or glycerine, which are released from the
aerosol-forming substrate upon heating. The solid tobacco material
is macerated in the liquid to impart tobacco flavour compounds
which are also released upon heating.
[0094] An exploded view of the cartridge 700 is shown in FIG. 8. As
will be appreciated, the canister 702 is not shown for simplicity
and clarity.
[0095] FIGS. 9(a), 9(b) and 9(c) show an aerosol-generating device
900 for use with the cartridge 700. The aerosol-generating device
is similar to device 200 shown in FIG. 2. The device comprises a
main body 902 comprising a power supply and control electronics
(not shown), an air inlet 904 and a heater assembly 906. The device
further comprises a detachable mouthpiece portion 908 having an air
outlet 910 and a transparent section 912 for receiving the
cartridge 700. In use, the user inserts the cartridge onto the
heater assembly, as shown in FIG. 9(b). The heater assembly,
described in further detail below with reference to FIG. 10,
pierces the seal 708 and engages with the liquid delivery assembly
of the cartridge 700. The user then attaches the mouthpiece portion
908, as shown in FIG. 9, to complete the assembly of the device.
The transparent section 912 enables the user to view the cartridge
700, and therefore the solid tobacco material 720 provided
therein.
[0096] The heater assembly 906, shown in FIG. 10, comprises a
heater mount 1000, a hollow piercing element 1002, and an
electrical heating element 1004. The electrical heating element is
provided with electrical contacts 1006 and 1008 configured to
electrically couple the heating element to the power supply via the
control electronics. The heating element 1004 is provided
transverse the longitudinal axis of the piercing element 1002 in a
through hole 1010.
[0097] In use, when the cartridge 700 is received in the device
900, the through hole 1010 is in fluid communication with the
liquid delivery assembly of the cartridge. In this way, liquid is
provided to the heating element 1004 to be aerosolised upon
heating. An airflow pathway is formed from the air inlet 904,
through the hollow piercing element 1002 of the heater assembly
1000 and over the heating element 1004, through the central hollow
portion 704 of the cartridge, and out of the air outlet in the
mouthpiece. When power is provided to the heating element 1004 the
liquid is vaporised, and by capillary action, replaced with further
liquid by the liquid delivery assembly.
* * * * *